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Foreword

Welcome to value-conscious company. We are proud of the advanced engineering and


quality construction of each equipment we manufacture.
This manual explains the working of equipment. Please read it thoroughly and have all
the occupants follow the instructions carefully. Doing so will help you enjoy many years
of safe and trouble free operation.
When it comes to service remember that K.C. Engineers knows your equipment best
and is interested in your complete satisfaction. We will provide the quality maintenance
and any other assistance you may require.
All the information and specifications in this manual are current at the time of printing.
However, Because of K.C. Engineers policy of continual product improvement we
reserve the right to make changes at any time without notice.
Please note that this manual explains all about the equipment including options.
Therefore you may find some explanations for options not installed on your equipment.
You must follow the instructions and maintenance instructions given in the manual
carefully to avoid possible injury or damage. Proper maintenance will help ensure
maximum performance, greater reliability, and longer life for the product.

K.C. Engineers

Contents
1.

Objective

2.

Aim

3.

Introduction

4.

Theory

5.

Description

6.

Utilities Required

7.

Experimental Procedure

8.

Observation & Calculation

9.

Nomenclature

10

10.

Precautions & Maintenance Instructions

11

11.

Troubleshooting

12

12.

Reference

12

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

FOUR CYLINDER FOUR STROKE PETROL ENGINE


TEST RIG
(WITH HYDRAULIC BRAKE DYNAMOMETER AND MORSE TEST ARRANGEMENT)

1.

OBJECTIVE:
To study the Multi cylinder four stroke petrol engine & its characteristics.

2.

AIM:
To determine
Brake Power
Fuel consumption
Specific fuel consumption
Brake thermal efficiency
Indicated Power
Mechanical efficiency
Swept volume
Air consumption
Volumetric efficiency
Heat balance sheet

3.

INTRODUCTION:
The most commonly used source of power for motor vehicles, introduced by the
German engineers Gottlieb Daimler and Karl Benz in 1885. The petrol engine is a
complex piece of machinery made up of about 150 moving parts. It is a reciprocating
piston engine, in which a number of pistons move up and down in cylinders. A
mixture of petrol and air is introduced to the space above the pistons and ignited. The
gases produced forces the pistons down, generating power. The engine-operating
cycle is repeated every four strokes (upward or downward movement) of the piston,
this being known as the four-stroke cycle. The motion of the pistons rotates a
crankshaft, at the end of which is a heavy flywheel. From the flywheel the power is

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

transferred to the vehicles driving wheels via the transmission system of clutch,
gearbox, and final drive.

4.

THEORY:
The Four Stroke Cycle
The stroke is simply when the piston moves either all the way up or all the way
down inside the cylinder. As you might guess, in the four-stroke engine each of the
four strokes accomplishes something different. Therefore, lets have a look at the four
strokes and see what happens:
Induction
The first stroke is called Induction. This is when the fuel and air mixture is drawn into
the cylinder by the piston going down and producing suction. As the piston travels
down the cylinder it creates a vacuum above it and the fuel mixture is drawn into the
cylinder in the empty space left by the piston The piston starts at the top, the camshaft
turns and pushes the tappets which causes the intake valve to open (on the left), and
the piston moves down to let the engine take in a cylinder full of air and fuel. This is
also sometimes called the intake stroke.
Compression
Compression is the second of the four strokes. This is the stage when the fuel and air
mixture is compressed and forced into the top of the cylinder ready for ignition. The
camshaft has turned, pushed the tappets, which has in turn allowed the inlet valve to
return to the closed position. The piston moves back up and compresses this fuel/air
mixture. Compressing the mixture makes the explosion more powerful. As the valves
are both closed, the cylinder is sealed and the mixture cant escape.
Ignition
As the piston reaches the top of the compression stroke, the spark plug fires and
ignites the highly compressed fuel and air mixture. The piston is then forced back
down the cylinder by the resulting explosion, turning the crankshaft and generating
the propulsion for the engine that makes the vehicle to go along the road. The
diagram shows the piston on its way down the cylinder just after the mixture has
ignited.

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

Exhaust
This is when the exhaust gases (after the fuel is burnt) are forced out of the engine.
Once the piston hits the bottom of its stroke, the exhaust valve opens (on the right).
The piston travels back up inside the cylinder and this time it pushes the exhaust
gasses out through the now open exhaust vent. Now the engine is ready for the next
cycle, so it intakes another charge of air and gas. And we are back to the intake
stroke.
Multiple Cylinders
The vast majority of internal combustion engines used more than one cylinder. This is
entirely a question of efficiency. The limitation of the Otto Cycle is that it only
provides power to turn the crankshaft a quarter of the time. The logical solution is to
have four cylinders with pistons turning the crankshaft so at any time there is always
one cylinder in the power stroke and the crankshaft is turned at a fairly even rate. An
even more powerful method is to use extra cylinders at intermediate points in the
cycle so that one power stroke starts before the previous one has finished.

5.

DESCRIPTION:
Four Cylinders, Four Stroke, Petrol Engine Test Rig with hydraulic brake
dynamometer arrangement mainly consists of:
1. A Four Cylinder, Four Stroke petrol engine,
2. A Hydraulic brake dynamometer arrangement,
3. A Panel Board Arrangement,
4. A Fuel Input Measuring Arrangement,
5. Air intake measuring arrangement.
6. An Arrangement for measuring the heat carried away by cooling water from
engine jacket.
7. An Arrangement for measuring the heat carried away by exhaust gases.
A brief description and particulars on this test rig is given below:
MULTICYLINDER PETROL ENGINE:
A medium capacity four cylinder, four strokes, water-cooled, petrol engine is
selected for experimental purposes. The specification for the Engine is as follows:
Engine : 4 cylinder, 4 stroke, inclined, water cooled

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

The engine is complete with self-starter, dynamo, lube-oil filter, air cleaner,
distributor, ignition coil etc.
HYDRAULIC BRAKE DYNAMOMETER.
Hydraulic brake dynamometer works on the principle of dissipating the power in
fluid friction rather than in dry friction. In principle its construction is similar to that
of a fluid flywheel. It consists of an inner rotating member or impeller coupled to the
output shaft of the engine. This impeller rotates in a casing filled with fluid. This
outer casing, due to centrifugal force developed, tends to revolve with impeller, but is
resisted by a torque arm supporting the balance weight. The frictional forces between
the impeller and the fluid are measured by the spring balance fitted on the casing the
heat developed due to dissipation of power is carried away by a continuous supply of
the working fluid, usually water. Regulating the sluice gates, which can be moved in
and out to partially or wholly obstructive flow of water between impeller and the
casing, can control the output.
PANEL BOARD ARRANGEMENT:
The units fitted on the Panel board are:
a.) An ignition and starting switch to switch on the ignition circuit and to start the
engine.
b.) A Pilot lamp indicator for ignition.
c.) A high voltage knife switches assembly for cutting of each cylinder for Morse
Test. With the help of the four individual knife switches each cylinder can be cut
off.
d.) Throttle valve control mechanism to control the position of the throttle in relation
to the speed and load on the engine.
FUEL INPUT MEASURING ARRANGEMENT:
Consists of self-mounting type fuel tank of about 10 liters capacity suitably mounted
on a stand. The stand fixed on the air tank, fuel goes from the reservoir to fuel filter
through a 100 ml burette. The burette facilitates the measurement of the fuel
consumption for a definite period of time with the help of a stopwatch.
AIR INTAKE MEASURING ARRRANGEMENT:
Consists of an air tank fitted on orifice plate with orifice and a manometer to measure
the flow rate of air sucked by the engine. The co-efficient of discharge of orifice is
about 0.64.

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

ARRANGEMENT FOR MEASURING THE HEAT CARRIED AWAY BY


COOLING WATER:
Suitable piping system is fitted to the engine for circulating the cooling water for the
engine. Thermocouples are provided to measure the inlet and outlet temperature of
cooling water. For measuring the rate of flow of cooling water, a water meter is
provided. With these entire arrangements one can find the heat carried away by
cooling water.
ARRANGEMENT FOR MEASURING THE HEAT CARRIED AWAY BY
EXHAUST GASES:
It consists of exhaust gas calorimeter to measure the heat carried away by exhaust
gases. Exhaust gas calorimeter consists of a central tube and an outer jacket. Exhaust
gases passes through central tube and water is circulated in outer jacket to get the
maximum Temperature difference of exhaust gases at inlet and outlet of calorimeter.
The volume of water circulation is measured with the help of measuring cylinder and
stopwatch. Thermocouples are provided to get the inlet and outlet temperature of
exhausts gases and water circulated.

6.

UTILITIES REQUIRED:
1. Electricity supply: Single phase, 220V AC, 50 Hz, 5-15 Amp socket with earth
connection
2. Water Supply continuous @10 LPM at 1 Bar for engine & exhaust gas calorimeter
cooling.
3. Water Supply continuous @10 LPM at 2 Bar for Hydraulic brake dynamometer.
4. Drain Required.
5. Petrol: 10 liters.
6. Engine oil: Multi grade 20W40 4.5 liters.
7. Floor Area Required: 3 m x 1.5 m.
8. Exhaust Emission.
9. Tachometer for RPM measurement.

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

7.

EXPERIMENTAL PROCEDURE:
1. Fill oil in the oil sump of engine. It should be in between the marks provided on
the oil dipstick. If oil level is reduced, add clean oil (SAE40) to the crankcase by
opening the cover, provided at the top of the engine.
2. Fill the petrol in petrol tank.
3. Fill the manometer fluid i.e. water, up to half of the height of manometer.
4. Fill the burette with petrol and supply the petrol to the engine by opening the
valve provided at the left side of burette.
5. Switch on Mains Power Supply to the panel.
6. Open cold water supply to the engine jacket and exhaust calorimeter.
7. Open the cold water supply for hydraulic brake dynamometer.
8. Insert the ignition key and turn it in the clockwise direction to ignition on position,
which is indicated by an indicator lamp. Turn the ignition switch key further
clockwise against the spring pressure to start the engine. As soon as the engine
starts, leave the ignition key and it run for 2 minutes under no load condition.
9. When engine start running smoothly, firstly load on engine with the help of
Hydraulic brake dynamometer.
10. Run the engine 2 minutes so that it can stabilize.
11. Note down the reading of load on the output shaft of the dynamometer and note
the RPM.
12. For measuring fuel consumption close the petrol supply valve provided on left
side of burette so that fuel flows from burette. Note down the time to consume 10
or 20 ml of petrol.
13. Now open the fuel supply valve which refill the burette and continue the petrol
supply.
14. Note down the reading of manometer to calculate the air consumption by the
engine.
15. Note the temperature of inlet and outlet of the water circulating through the engine
jacket with the help of thermocouple.
16. Measure the flow rate of water circulating through the engine jacket from water
meter with the help of stop -watch.

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

17. Note down the temperature of inlet and outlet of exhaust gases & water circulating
through the calorimeter. Measure the flow rate of water circulating through
calorimeter with the help of water meter and stopwatch.
18. Repeat the experiment for different load.
19. Now for the Morse test, cut off the required cylinder by the respective knife
switch. Adjust the speed of the engine to its original value by reducing the load
from the dynamometer without changing the throttle position.
20. Repeat the same procedure for cutting other cylinder by the respective knife
switch.
21. When the experiment is over firstly engage all cylinder and reduce the load on
engine by removing the weights of the dynamometer and reducing the throttle
gradually
22. Turn off the ignition key and remove it from the switch.
23. Then close the fuel and cooling water supply to the engine.

8.

OBSERVATION & CALCULATION:


DATA:
f

720 kg/m3

1.21 Kg / m 3

1000 kg/m3

Cd

0.64

CV

44650 kJ/kg

Cp

4.186 kJ/kgoC

EQUIPMENT DATA:
do

0.027 m

ao

0.0005726 m2

0.084 m

0.082 m

NC

2( for 4-stroke cycle)

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

OBSERVATION TABLE:
Ta =

______________ oC (Reading of sensor T3/T4 before starting the engine)

S.No.

1.

2.

3.

4.

W
RPM
x (ml)
t sec.
T1 oC
T2 oC
VE litres
tE Sec
T3 oC
T4oC
T5 oC
T6 oC
VC liters
tC Sec
h1, cm
h2, cm
MORSE TEST:
S.No.
Cutting off cylinder no.

1
1.

2.

2.
3.

4.

1.

2.

3.
3.

4.

1.

2.

3.

4.

W
RPM

BP =

W * N * 0 .746
, kW
2000

-------------- kW

Wf =

x f
*
, kg/sec
t 10 06

-------------- kg/sec

-------------- kg/kW-sec

Wsf =

Wf
BP

, kg/kW-sec

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

H f = W f * C v , kW

-------------- kW

BT =

BP
*100 , %
Hf

-------------- %

m EW =

VE W
*
, kg/sec
t E 10 03

H E CW = m E W * C P * (T2 T1 ) , kW

mCW =

VC W
*
, kg/sec
t C 10 03

-------------- kg/sec
=

-------------- kW

-------------- kg/sec

H CCW = mCW * C P * (T6 T5 ) , kW

-------------- kW

H exh = mexh * C exh * (T3 Ta ) , kW

-------------- kW

mCW * CP * (T6 T5 ) = mexh * C exh * (T3 T4 )


or mexh * C exh =

mCW * C p * (T6 T5 )
(T3 T4 )

H un = H f ( BP + H ECW + H exh ) , kW
Where a0 =

H=

h1 h2
100

-------------- m2

1 ,m

-------------- m

* D2 * L * N * Nc

vol . =

-------------- kW

* d 0 , m2

Qa = Cd * aO 2 gH ,m3/sec =
Vs =

4 * 60 * n

Qa
* 100 , %
Vs

,m3/sec

-------------- m3/sec
=

-------------- m3/sec

-------------- %

MORSE TEST:
When cutting off first cylinder
BP1 =

N * W * 0.746
, kW
2000

-------------- kW

IP1 = BP BP 1
Similarly Indicated Power (I.P.) of the remaining three cylinders is:
IP2 = BP BP2
IP3 = BP BP3

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

IP4 = BP BP4
IP = IP1 + IP2 + IP3 + IP4

mech. =

IT =

9.

BP
* 100 , % =
IP

IP
* 100 , %
Hf

-------------- %
-------------- %

NOMENCATURE:
BP

Brake power, Kw

Acceleration due to gravity , m/s2

Revolutions per minute

Torque, Nm

Re

Mean effective radius, m

Load cell reading, kg

Wf

Fuel consumption, kg/sec

Volume of fuel consumed, ml

Time taken to consume x ml of fuel, sec

Wsf

Specific fuel consumption, kg/ kW-sec

Hf

Heat supplied by the fuel, kW

CV

Calorific value of fuel kj/kg

BT

Brake thermal efficiency

HECW =

Heat carried out by water from engine cooling jacket., kW

mEW

Mass of water entering the engine cooling jacket per sec,kg/sec

Cp

Specific heat of water, kj/kg-oC

VE

Volume of water entering the engine cooling jacket for given time, litrs

tE

Time for VE.,sec

Hun

Unaccounted heat or heat lost in radiation, kW

Density of water, kg/m3

HCCW =

Heat carried by water from calorimeter from exhaust gases, kW

mCW

Mass of water entering calorimeter per sec , kg/ sec

VC

Volume of water entering the calorimeter for given time, liters

tC

Time for VC , sec

Hexh

Heat carried out by exhaust gases, kW

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

10

Cexh

Specific heat of exhaust gases

Qa

Air consumption, m3/sec.

Cd

Co-efficient of discharge.

ao

Area of orifice, m2.

do

Diameter of orifice, m.

h1, h2 =

Manometer reading, cm.

Manometer fluid density, kg/m3.

Density of air, kg/m3.

VS

Swept Volume, m3/sec.

Stoke length of engine, m.

Diameter of cylinder, m.

NC

Number of cylinder.

Number of cycles.

Vol.

Volumetric efficiency, %.

IP

Indicated Power, kW.

mech

Mechanical efficiency, %.

IT

Indicated thermal efficiency, %.

T1

Temperature of water inlet for Engine jacket in oC

T2

Temperature of water outlet from Engine jacket in oC

T3

Temperature of exhaust inlet for calorimeter in oC

T4

Temperature of exhaust outlet from calorimeter in oC

T5

Temperature of water inlet for calorimeter in oC

T6

Temperature of water outlet from calorimeter in oC

Ta

Ambient temperature in oC

10. PRECAUTIONS & MAINTENANCE INSTRUCTIONS:


1. Always check the oil level in the engine before starting and make sure that
sufficient oil is present in the engine.
2. Change the oil as engine completes approx.100 hours of total running.
3. Open cold water supply to the engine before starting the engine.
4. Fuel tank and fuel line should be clean and free from foreign particles.
5. The Morse test should be carried out only after the engine running conditions are
stabilized at the required BP.

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

11

6. When a cylinder is cut off adjust the speed and load of the engine quickly because
large time laps might result in the change in the working conditions of the engine.
7. Do not attempt to cut off two cylinders simultaneously, since it can develop
severe engine vibration.

11. TROUBLESHOOTING:
1. If the engine heats up, check the water supply to the engine jacket.
2. If engine does not start and the battery indicator not glow, check the battery if
discharged, charge it.
3. If still engine does not start, check the fuel and fuel supply line. If air found in
pipeline, remove it.

12. REFERANCES
1. M.L. Mathur & R.P. Sharma, A Course in Internal Combustion Engine, 7th
ed., Dhanpat Rai Publication Asian Books ltd., ND, 2000.

Four Cylinder Four Stroke Petrol Engine with hydraulic dynamometer Test Rig

12

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